Coupling Analysis Based On The Thermodynamic Order Fast Roll Casting Process Of Aluminum Sheet Finite Element Simulation Study

Aluminum processing industry is developing quickly in our country, the high-newly technology of super-thin and high-speed roll casting has a great latent market. It is a newly developing technology , many new technologies are used in roll casting technics. The matter of thermal-mechanical coupling in the process of roll casting is discussed in this paper. The aim of this paper is to find a method to analyze the multi-nonliner thermal-mechanical coupling processing of super-thin aluminum board roll casting. Such problem is solved by the way of analyzing each alone then taking them together using the balance and harmonize conditions.In the process of roll casting, there are three state in roll casting zone: liquid, semi-solid and solid. In order to follow the existing elastic and plastic mechanics FEM in the modeling process, the process of roll casting is analyzed include both solid and liquid field. To avoid calculating convergence trouble, and even stiffness matrix singularity due to great disparity in stiffness of differ state cells in the calculated field, some assumptions have been made on the mechanics characteristic of liquid aluminum, so the stress state of the liquid is near to the hydraulic pressure. The problem in which liquid and solid are coexisted is solved. And the finite element model for the roll casting process has been established. In the course of iterative calculating of the thermal analyticresults with the mechanics, by remeshing technology has been used for the realization of field information transfer between two model. Then the thermal-mechanic coupling analyse in the roll casting process has been completed, and relative user programs same exploited. Several work conditions are simulated by the user programs, and the rules of metal stress, metal strain and metal flow in the process of roll casting are obtained. Simulating results are compared with many work conditions, and discussions are made for the affect of many process parameters one another. These progenies are helpful in comprehending and improveing roll casting technology.Industrial experiment of super-thin and high speed roll casting was done , the experimental results are basically fit for the FEM simulating results, which demonstrates that the FEM model and the thermal-mechanical coupling method developed in the paper is correct, so the conclusion of this paper is reliable.